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A New Method of Flanges Extrusion in Hollow Products – Analysis of the Limiting Phenomena

Winiarski Grzegorz, Bulzak Tomasz Adam, Wójcik Łukasz, Szala Mirosław

Advances in Science and Technology. Research Journal

2020

Vol. 14, no 4

78--85

The paper presents an innovative method of metal forming of hollow flanged elements. In this process, flanges are formed using a movable sleeve, which moves in the opposite direction to the punch. The movement of the sleeve causes a closed impression to open, due to which the flange is also formed in a semi-free impression. The tube billets were made of the 42CrMo4 grade steel deformed under the cold metal forming conditions. The calculations were conducted using the finite elements method in Deform-2D/3D. Various technological parameters of the process were analysed, among others the diameter of the flange and the initial height of the impression of the movable sleeve. On the basis of the obtained results, the limiting phenomena of the process were determined and the influence of the analysed technological parameters on these phenomena were presented.

Effect of Tool Kinematics on Tube Flanging by Extrusion with a Moving Sleeve

Winiarski Grzegorz, Bulzak Tomasz Adam, Wójcik Łukasz, Szala Mirosław

Advances in Science and Technology. Research Journal

2019

Vol. 13, no 3

210--216

This paper presents the results of a numerical investigation into tube flanging by extrusion with a moving sleeve. Two cases of the extrusion process are investigated, each described with a different tool kinematics. Effects of flange diameter, gap height and tool motion on the extrusion process are examined. The numerical analysis is performed on 42CrMo4 steel tubes deformed at ambient temperature. Obtained numerical results are then used to determine metal flow patterns and examine force parameters in the extrusion process, as well as to determine a technological window for the investigated method.